U.S. patent application number 13/294899 was filed with the patent office on 2012-05-17 for internal support structure for an athletic support bra, and associated method of fabrication.
This patent application is currently assigned to Sturdy Girl Sports, LLC. Invention is credited to Hilary Heath, Susan Krueger.
Application Number | 20120122370 13/294899 |
Document ID | / |
Family ID | 46048187 |
Filed Date | 2012-05-17 |
United States Patent
Application |
20120122370 |
Kind Code |
A1 |
Heath; Hilary ; et
al. |
May 17, 2012 |
Internal Support Structure For An Athletic Support Bra, And
Associated Method Of Fabrication
Abstract
A support structure for a bra includes a two-ply structural
support layer having an m-shaped ply of compression fabric, forming
left and right openings along a bottom aspect of the m-shaped ply,
and a w-shaped ply of compression fabric, forming left and right
openings along a top aspect of the w-shaped ply. The m- and
w-shaped plies are joined together such that the left and right
openings of each ply overlap to form left and right pockets for
accommodating at least a portion of a wearer's left and right
breasts. The support structure encapsulates and separates the
breasts. When joined with straps of a sports bra or top, the
two-ply structural support layer provides sling-type support of the
breasts. Compressive fabric of the bra or top compresses the
breasts to a wearer's chest; thus, a bra or top incorporating the
support structure provides three-way support via encapsulation,
suspension and compression.
Inventors: |
Heath; Hilary; (Louisville,
CO) ; Krueger; Susan; (Providence, RI) |
Assignee: |
Sturdy Girl Sports, LLC
|
Family ID: |
46048187 |
Appl. No.: |
13/294899 |
Filed: |
November 11, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61413181 |
Nov 12, 2010 |
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Current U.S.
Class: |
450/80 ;
450/93 |
Current CPC
Class: |
A41C 3/0057 20130101;
A41C 3/0021 20130101 |
Class at
Publication: |
450/80 ;
450/93 |
International
Class: |
A41C 3/12 20060101
A41C003/12 |
Claims
1. A two-ply structural support layer for a bra, comprising: an
m-shaped ply of compression fabric forming left and right openings
along a bottom aspect of the m-shaped ply; and a w-shaped ply of
compression fabric forming left and right openings along a top
aspect of the w-shaped ply; the w-shaped ply joined with the
m-shaped ply such that the left and right openings in the w-shaped
ply overlap with left and right openings in the m-shaped ply to
form left and right pockets for accommodating at least a portion of
a wearer's breasts.
2. The structural support layer of claim 1, further comprising left
and right nipple covers attached with the two-ply structural
support layer to cover the left and right pockets and minimize
appearance of the wearer's nipples.
3. The structural support layer of claim 1, wherein the w-shaped
ply and the m-shaped ply are cut on different grains, and wherein
different stretches of the plies enhance bust support.
4. An internal support structure for a bra, comprising: a two-ply
structural support layer including: an m-shaped ply of compression
fabric forming left and right openings along a bottom aspect of the
m-shaped ply, and a w-shaped ply of compression fabric forming left
and right openings along a top aspect of the w-shaped ply; the
w-shaped ply joined with the m-shaped ply such that the left and
right openings of the plies overlap to form left and right pockets
for accommodating at least a wearer's nipples; and an interior
liner for contacting a wearer's skin; the liner joined with an
interior aspect of the two-ply structural layer and having left and
right molded cups fitted at least partially into the left and right
pockets, for accepting and encapsulating the wearer's left and
right breasts.
5. The internal support structure of claim 4, further comprising
left and right nipple covers attached with the two-ply structural
support layer to cover and pad the wearer's nipples.
6. The internal support structure of claim 5, further comprising a
layer of spacer fabric joined with the two-ply structural support
layer over the nipple covers, the spacer fabric further minimizing
appearance of the wearer's nipples.
7. The internal support structure of claim 4, further comprising a
layer of spacer fabric joined with an exterior side of the two-ply
structural support layer, for minimizing appearance of the wearer's
nipples.
8. The internal support structure of claim 4, wherein the w-shaped
ply and the m-shaped ply are cut on different grains.
9. An athletic support bra providing suspension, encapsulation and
compression, and comprising: an exterior front shell made of a
compressive fabric to reduce motion of a wearer's breasts during
exercise; a spacer layer beneath the exterior front shell, for
minimizing appearance of a wearer's nipples, camouflaging
underlying layers and enhancing breast compression; a two-ply
structural support layer beneath the spacer layer and including a
w-shaped ply of fabric and an m-shaped ply of fabric joined to form
left and right breast pockets; a liner layer beneath the two-ply
structural support layer, the liner layer including cups formed
from a spacer material and joined with the two-ply structural
support layer such that the cups fit at least partially within the
left and right pockets; left and right shoulder straps formed with
or joined with the exterior front shell and further joined with the
spacer layer, the two-ply structural support layer and the liner
layer; an exterior back side made with a compressive fabric and
joined with (a) the shoulder straps, and (b) at least the exterior
front shell; and elastic joined with a bottom border of the
athletic support bra to form a continuous ribcage band; wherein the
two-ply structural support layer and the liner layer encapsulate
the wearer's breasts, a juncture of the straps with the two-ply
structural support layer provides suspension support of the
breasts, and the compressive fabric compresses the breasts to the
wearer's chest.
10. The bra of claim 9, the two-ply structural support layer
further comprising left and right nipple covers positioned with the
left and right pockets, to cover and pad the wearer's nipples.
11. The bra of claim 9, wherein the w- and m-shaped plies of the
two-ply structural support layer are cut on different grains.
12. The bra of claim 9, wherein one of the m-shaped ply and the
w-shaped ply is cut straight grain from tech sheen fabric, and the
other of the m-shaped ply and the w-shaped ply is cut cross grain
from tech sheen fabric.
13. The bra of claim 9, the two-ply structural support layer
comprising a material selected from the group of tech sheen and
powernet.
14. The bra of claim 9, the exterior front shell comprising a
material selected from the group consisting of a compression jersey
fabric, a dense, 4-way stretch polyester COOLMAX.RTM. and
Lycra.RTM. technical fabric, and a fabric having 79% polyester
COOLMAX.RTM. and 21% Lycra.RTM..
15. The bra of claim 9, the liner layer comprising a material
selected from the group of a nylon/spandex fabric blend, a spongy
90% nylon/10% spandex material, tech sheen, a material including
75-80% denier nylon and 20-25% Lycra.RTM., a soft stabilizing
tricot, and a spacer fabric.
16. The bra of claim 9, wherein the shoulder straps are lined with
spacer material, and wherein seams between the straps and the front
and back of the bra are offset from a top of the wearer's
shoulders, to reduce rubbing and chafing.
17. The bra of claim 9, the cups comprising seamless, molded
cups.
18. The bra of claim 9, wherein the two-ply structural support
layer provides superior, inferior, medial and lateral support to
the breasts.
19. The bra of claim 9, the cups molded by heat molding.
20. The bra of claim 9, wherein each cup is formed as a unitary
piece.
Description
RELATED APPLICATIONS
[0001] This application claims priority to Provisional Patent
Application No. 61/413,181, filed Nov. 12, 2010 and incorporated
herein by reference.
BACKGROUND
[0002] Women who have undergone breast augmentation surgery face a
challenge in finding a well-fitting sports bra to adequately
support their enhanced breasts. Post-augmentation, a woman's
breasts are often disproportionately large in comparison with the
circumference of her rib cage. While women with naturally large
breasts are typically also naturally larger in the rib cage area
and/or upper body, women with augmented breasts are often
proportionally smaller in the rib cage area and/or upper body, and
thus have a disproportionate upper body structure after surgery.
Many conventional sports bra cup and band dimensions tend to
increase proportionally (for example, sports bras that are sized
small, medium, large, etc. rather than specifically sized for cup
and band ratios), and therefore provide a poor fit for the
augmented figure.
[0003] Further, women with augmented breasts need more breast
tissue and ligament support than natural breasts, in order to
reduce ligament stretching and sagging over time. As women age,
both their breast tissue and the suspensory Cooper's ligaments lose
elasticity and thin. However, breast implants create a dense,
non-changing load on the progressively thinner and weaker Cooper's
ligaments. Without proper support, especially during exercise that
involves dramatic up and down or side to side motion, augmented
breasts may be even more susceptible to sagging than natural
breasts. Surgical intervention, implant replacement and/or breast
lift, is often required to fix implants that have sagged
drastically due to improper support.
[0004] A woman with augmented breasts may also experience increased
nipple protrusion due to numbness or loss of sensation in nipple
tissue--a common side effect of augmentation, occurring in greater
than 50% of surgeries. As a result, the nipples are often erect at
embarrassing times. Workouts are no exception.
SUMMARY
[0005] Disclosed herein is an athletic support bra or other
athletic active-wear garment (e.g., a sports tank or other top)
including a two-ply structural support layer. The structural
support layer includes a roughly "m" shaped ply layered with a
roughly "w" shaped ply such that openings formed by the m and w
shapes overlap to create pockets for accommodating at least the
nipple area of a wearer's breast, and optionally, the entire
breast. The m and w plies are cut on different grains to provide
different stretch and support in each ply, thus enhancing overall
support of the structural support layer. The structural support
layer provides a high level of support and motion control for
larger sized breasts, for example during exercise. In particular,
the support layer properly supports and fits an augmented physique,
although the support layer also offers improved support for women
with naturally large breasts. A sports bra or sports top
incorporating the two-ply structural support layer provides
three-way support to a wearer, via breast compression,
encapsulation and suspension. For example, the structural support
layer provides encapsulation and suspension (i.e., via connections
to straps) while an outer fabric layer compresses the breasts and
breast area of a wearer.
[0006] A bra incorporating the structural support layer includes a
spacer fabric lining material or other materials that effectively
reduce the appearance of nipple protrusion when molded and sewn
into a sports bra or top, affording the wearer with some modesty
during exercise. The spacer fabric may be naturally wicking due to
the construction of component yarns, and/or may be treated with a
moisture management agent that helps to wick sweat from the skin
while the wearer is exercising and perspiring. Additional nipple
covers attached with the structural support layer further smooth
the silhouette of a wearer.
[0007] In another aspect, the two-ply support layer is replaced by
a support structure with a figure eight construction and provides a
high level of support and motion control for larger sized breasts,
during exercise. A sports bra or sports top incorporating the
figure eight support structure also provides three-way support to a
wearer, via breast compression, encapsulation and suspension.
[0008] In one embodiment, a two-ply support layer for a bra
includes an m-shaped ply of compression fabric forming left and
right openings along a bottom aspect of the ply, and a w-shaped ply
of compression fabric forming left and right openings along a top
aspect of the ply. The w-shaped ply joined with the m-shaped ply
such that the left and right openings in the plies overlap to form
left and right pockets for accommodating at least the nipples of a
wearer's left and right breasts.
[0009] In one embodiment, an internal support structure for a bra
includes a two-ply structural support layer and an interior liner
for contacting a wearer's skin. The two-ply structural support
layer has an m-shaped ply of compression fabric forming left and
right openings along a bottom aspect of the m-shaped ply, and a
w-shaped ply of compression fabric forming left and right openings
along a top aspect of the w-shaped ply. The w-shaped ply joined
with the m-shaped ply such that the left and right openings of the
plies overlap to form left and right pockets for accommodating at
least a wearer's nipples. The interior liner joins with an interior
aspect of the two-ply structural layer and has left and right
molded cups fitted with and into the left and right pockets, for
accepting and encapsulating the wearer's left and right
breasts.
[0010] In one embodiment, an athletic support bra for providing
suspension, encapsulation and compression includes an exterior
front shell made of a compressive fabric to reduce motion of a
wearer's breasts during exercise. A spacer layer beneath the
exterior front shell minimizes appearance of a wearer's nipples,
camouflages underlying layers and enhances breast compression. A
two-ply structural support layer beneath the spacer layer includes
a w-shaped ply of fabric and an m-shaped ply of fabric joined to
form left and right breast pockets. A liner layer beneath the
two-ply structural support layer includes left and right cups
formed from a spacer material and joined with the two-ply
structural support layer such that at least a portion of the left
cup fits within the left pocket and at least a portion of the right
cup fits within the right pocket. Left and right shoulder straps
are formed with or joined with the exterior front layer and further
joined with the spacer layer, the two-ply structural support layer
and the liner layer. An exterior back side made with a compressive
fabric is joined with (a) the shoulder straps, and (b) at least the
exterior front shell. Elastic joined with a bottom border of the
athletic support bra forms a continuous ribcage band. The two-ply
structural support layer and the liner layer encapsulate the
wearer's breasts, the juncture of the straps with the two-ply
structural support layer provides suspension support of the
breasts, and the compressive fabric compresses the breasts to the
wearer's chest.
[0011] In one embodiment, an athletic support bra provides
suspension, encapsulation and compression, and includes an exterior
front layer made of a compressive fabric to reduce motion of a
wearer's breasts during exercise. A middle support structure is
joined with the exterior layer and includes a plurality of support
bands joined together to form a figure-eight structure bordering
right and left pockets. The joined support bands provide suspension
support and encapsulation of the wearer's breasts. A liner layer
includes seamless, molded cups formed from a spacer material and
joined with the middle support structure such that the molded cups
fit within the right and left pockets to enhance encapsulation of
the breasts. Left and right shoulder straps join with the exterior
layer, the middle support structure and the liner layer at a front
seam above the molded cups. An exterior back side made with a
compressive fabric joins with (a) the shoulder straps at seams
corresponding with a wearer's upper back, and (b) at least the
exterior front layer and the liner layer of the combined front
layer, support structure and liner layer front layer. Woven elastic
joins with a bottom border of the athletic support bra to form a
continuous ribcage band.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows an exterior front side of an athletic support
bra, according to an embodiment.
[0013] FIG. 2 is an exterior back view of the bra of FIG. 1.
[0014] FIG. 3 shows an inner, front lining of the bra of FIGS. 1
and 2, according to an embodiment.
[0015] FIG. 4 is a front view of a two ply structural middle layer,
found between the exterior front side of FIG. 1 and the lining of
FIG. 3, according to an embodiment.
[0016] FIG. 5 is a front view a first, w-shaped ply of the
structural middle layer of FIG. 4.
[0017] FIG. 6 is a front view a second, m-shaped ply of the
structural middle layer of FIG. 4.
[0018] FIG. 7 is a front view of the structural middle layer of
FIG. 4 assembled with nipple covers, according to an
embodiment.
[0019] FIG. 8 is a pre-assembly view of the front side of the bra
of FIG. 1, showing an additional spacer layer between the
structural middle layer of FIG. 4 and the front side of FIG. 1,
according to an embodiment.
[0020] FIG. 9 is an inner view of the front side of the bra of FIG.
1, assembled with the supportive middle layer of FIG. 4.
[0021] FIG. 10 is an inner view of the front side of the bra of
FIG. 1, assembled with the inner lining of FIG. 3.
[0022] FIG. 11 shows a sports bra incorporating a supportive middle
layer, according to an embodiment.
[0023] FIG. 12 is a front view of an alternately designed athletic
sports bra, according to an embodiment.
[0024] FIG. 13 is a back view of the sports bra of FIG. 12.
[0025] FIG. 14 is a front view of an alternately designed athletic
sports bra, according to an embodiment.
[0026] FIGS. 15 and 16 are respective front and back views of a
sports tank incorporating an athletic sports bra, according to an
embodiment.
[0027] FIGS. 17 and 18 are respective front and back views of an
alternately designed sports tank incorporating an athletic sports
bra, according to an embodiment.
[0028] FIG. 19 is a flow chart depicting a method of fabricating an
athletic support bra, according to an embodiment.
[0029] FIG. 20 is a flow chart depicting another method of
fabricating an athletic support bra, according to an
embodiment.
DETAILED DESCRIPTION
[0030] FIGS. 1 and 2 show an athletic support bra (or sports bra)
100. In one embodiment, sports bra 100 includes a multi-layer front
side 102 (FIG. 1) that joins with a back side 104 (see also FIG.
2). An exterior layer or shell 103 of front side 102 faces outward
towards the viewer in FIG. 1. An inner liner layer, a two-ply
structural layer and a spacer layer of front side 102 are shown and
described with respect to FIGS. 3-8. Although shown as separate
pieces, it will be appreciated that front and back sides 102 and
104 may alternately be formed of a unitary exterior shell that is
joined together at the sides of the bra, for example, along seams
under a wearer's armpits.
[0031] Shell 103 is formed with a compression fabric to reduce
motion by pressing a wearer's breasts against her chest. In one
example, shell 103 includes a compression jersey fabric such as a
dense, 4-way stretch polyester COOLMAX.RTM. and Lycra.RTM.
technical fabric to compress and manage moisture during exercise.
Back side 104 of bra 100 may also be made of a wicking, compression
jersey fabric to enhance compression and moisture management. Back
side 104 may additionally be lined with a low stretch tech sheen
fabric. Wicking properties of exterior shell 103 and/or back 104
draw moisture from within bra 100 to the exterior of bra 100, to
facilitate evaporation, cooling and drying. Additionally, exterior
shell 103 and/or back side 104 may include a variety of functional
and/or decorative materials. As shown, exterior shell 103 has an
inset panel 106 of contrasting fabric (contrasting with the
majority fabric of exterior shell 103), and back 104 has an inset
panel 108 of a contrasting fabric. It will be appreciated that size
and shape of contrasting fabrics may vary without departing from
the scope hereof. Further, contrasting fabrics may provide contrast
in appearance without sacrificing compression and moisture
management properties of bra 100. In one aspect, panels 106 and 108
are made with a compression jersey fabric (i.e., the dense, 4-way
stretch polyester COOLMAX.RTM. and Lycra.RTM. technical fabric
mentioned above) that bears a print different from fabric used
elsewhere on front 102 and back 104. Panel 108 (and the entire back
and straps of other bra designs shown and described herein) may
also be lined with tech sheen for additional support.
[0032] In another aspect, panels 106 and 108 are made with mesh,
such as a single mesh polyester and spandex fabric, to enhance
compression. In one example, mesh panels 106 and 108 are a single,
82% polyester and 18% spandex mesh or other lightweight, breathable
and wicking mesh. Alternately or additionally, bra 100 may include
one or more cut-outs (e.g., in the back, along one or more shoulder
straps, above a bra-band or elsewhere).
[0033] Bra 100 is shown with a v-neck, racer back shape. However,
it will be appreciated that the appearance of bra 100 is not
limited to the drawings. Bra 100 may take on an alternate
appearance without departing from the scope hereof, for example, a
scoop neck or square neck, a cross-back or a standard back where
straps do not cross or join together. Bra 100 may also incorporate
front, side or rear openings or mesh panels (for example, above
band 112) to facilitate ventilation and cooling.
[0034] Bra 100 includes two shoulder straps 110 and a band 112 for
snugly fitting with a wearer's ribcage. Together, straps 110 and
band 112 secure and anchor bra 100 with the wearer's body. Band 112
and straps 110, together with support features described further
with respect to FIGS. 3-8, support and protect a wearer's breasts
from undue movement (i.e., due to running, jumping or other
exercise) through combined compression, suspension and
encapsulation of the breasts. Stitching 114, illustrated by dotted
lines, joins various materials and/or layers of bra 100. Stitching
114 for example joins exterior shell 103 with middle and inner
front layers of bra 100 (described with respect to FIGS. 3-5,
below). In another example, stitching 114 joins elastic or other
fabric of band 112, elastic or other fabric lining neck opening 116
and armholes 118, and/or fabric of panels 106 and 108 with the body
(i.e., primary material) of bra 100. It will therefore be
appreciated that where used herein, dotted lines represent
stitching 114, and do not necessarily indicate hidden structure.
However, lines 115, defining and extending above and to the sides
of panel 106 may represent either design detail or seams, even
though dotted lines are not used.
[0035] Shoulder straps 110 adjoin front side 102 with back side
104. Straps 110 may be continuous straps extending from a front
strap junction 119 to a back strap junction 121. Seams holding
straps 110 to front 102 and back 104 of bra 100 are for example at
front (upper chest) and back (upper back) junctions 119 and 121,
thus reducing rubbing and chafing at the top of the wearer's
shoulders.
[0036] In one aspect, straps 110 include an outer compression
fabric, an inner spacer material for cushioning, and a lining for
contact with the skin. Although fabric of straps 110 stretches
slightly to accommodate slight variances in body dimensions, straps
110 do not include any adjustable parts, thus preventing wear on
the user's skin and loosening of the straps during motion.
[0037] Band 112 may be a woven elastic rib band that is about
11/8-13/8'' wide. In one aspect, band 112 is 1 3/16'' in finished
width. Band 112 adjoins with front 102 and back 104 to encircle the
wearer's rib cage and support and uphold the wearer's breasts from
beneath. Band 112 may be constructed from woven ribbed elastic for
comfort and moisture management, and is sewn into bra 100 such that
it can either show front stitching detail (e.g., as shown in FIGS.
1 and 2) or appear to "float" within bra 100 without visible outer
stitching. Woven elastic of band 112 may lie directly against the
wearer's skin when bra 100 is worn.
[0038] FIG. 3 shows an inner, front liner layer 120 of bra 100.
Liner layer 120 (also referred to as "liner 120") forms a first,
innermost layer of front side 103 of bra 100. When bra 100 is worn,
liner 120 contacts the wearer's skin Liner 120 is shown with a skin
contact side 122 facing upwards, towards the viewer. Liner 120
includes two molded, seamless support cups 124. Cups 124 may be
heat molded or otherwise molded into a subtle bullet shape or
hollow sphere shape for fitting with each breast. Cups 124 enhance
encapsulation support of bra 100, and provide sufficient space for
the breasts to comfortably and supportively fit with bra 100
without undue squashing by compressive exterior shell 103 (FIG. 1).
It will be appreciated that the size and shape of cups 124 may vary
according to garment size (e.g., C cup, D cup, DD cup and the
like).
[0039] In one aspect, cups 124 are molded from nylon/spandex fabric
blend, for example a slightly spongy, 90% nylon, 10% spandex
material. In addition to encapsulating a wearer's breasts, the
spongy nature of cups 124 helps to minimize the appearance of
nipple protrusion and lends an overall smoother silhouette to the
wearer of bra 100. The material of cups 124 are naturally wicking
due to the construction and/or nature of the yarns used, but cups
124 may also be treated with a wicking agent to help draw moisture
away from the skin and transport it to the exterior of bra 100
(e.g., to exterior shell 103) for evaporation. Cups 124 may
likewise be made of tech sheen, a soft stabilizing tricot or
another active wear fabric such as lightweight wicking foam or
other material able to hold its shape after molding. Molding
advantageously eliminates seams within cups 124, thereby reducing
chaffing and discomfort and creating a yet smoother silhouette.
Liner fabric 125 above and between cups 124 may be the same as
material forming cups 124 (i.e., the slightly spongy, nylon/spandex
material mentioned above), or different from the material of cups
124. Cups 124 may be molded into a pre-cut, continuous liner 120,
or cups 124 may be molded into a continuous piece of liner fabric
which is then cut at its perimeter to dimensions and shape desired
for liner 120. Optionally, cups 124 are cut from the same or
different material from that forming the body of liner 20, and sewn
to liner 120. Although not shown in FIG. 3, liner fabric 125 may
also lie below and/or lateral to cups 124. Liner fabric 125 may
also include right and left strap liners, as described with respect
to FIG. 10, below.
[0040] As shown, liner 120 includes two upper, front panels 130
formed of fabric 125, between and above cups 124. Front panels 130
are joined at a center seam or centerline 134 such that left and
right sides of liner 120 are substantially symmetric about
centerline 134. Centerline 134 may be defined by one or more seams.
Alternately, as noted above, liner 120 may be formed of a
continuous piece of fabric into which cups 124 are molded.
[0041] FIG. 4 shows a structural, two-ply structural support layer
140 (also referred to herein as a 2-ply support layer, or simply a
support layer) of bra 100. FIGS. 5 and 6 separately show the plies
of support layer 140. FIGS. 4-6 are best viewed together with the
following description.
[0042] Two-ply structural support layer 140 is shown with a liner
contact side 142 facing towards the viewer. When bra 100 is
assembled, liner contact side 142 connects with a back side
(opposite skin contact side 122) of liner 120. A layer of spacer
fabric (described with respect to FIG. 8) contacts the side of
support layer 140 opposite liner contact side 142 when bra 100 is
assembled, such that support layer 140 is sandwiched between liner
120 and the spacer layer.
[0043] In one aspect, support layer 140 includes first and second
layers forming roughly the shape of a "W" and an "M", respectively.
As shown, liner contact side 142 has roughly an "M" shape; however,
it will be appreciated that the plies of structural support layer
140 may be reversed such that a "W" shaped ply of structural
support layer 140 contacts liner 120.
[0044] A w-shaped ply 144 (FIG. 5) includes a one-ply layer of
fabric (e.g., tech sheen) forming a rough "w" shape with two
cutouts 146. Ply 144 joins with band 112 of bra 100 at a bottom
edge 148, and for example joins with facing layers (liner 120 on an
inner side and an m-shaped ply 154 (FIG. 6) on the opposite side)
along broken top edge 150 and lateral edges 152. Plies 154 and 144
are referred to hereinafter as plies 154 and 144. In one aspect, m-
and w-shaped plies 154, 144 are at different grains from a
supportive material such as low stretch tech sheen. For example,
m-shaped ply 154 may be cut cross grain, while w-shaped ply 144 is
cut straight grain. When joined together, plies 154 and 144
establish breast separation about centerline 134 and create
circular or elliptical openings for accommodating at least the
nipples, up to the entire breast, of the wearer. Different grain
stretches of plies 154 and 144 enhance bust support of bra 100.
[0045] Plies 144 and 154 may be made of a tech sheen material
created of about 77% denier nylon and 23% Lycra.RTM.. In one
example, the nylon is EFA Style 5481 40/13 865 SD nylon. Such tech
sheen has very low up-and-down elasticity and stretchability and
moderate side-to-side elasticity and stretchability (and also
maintains its shape and support of the breasts over time). Cutting
one of plies 144, 154 straight grain and the other cross grain thus
enhances overall support, as areas of moderate stretch are
overlaid/underlaid with a lesser stretch cut of fabric.
Alternately, m-shaped ply 154 and w-shaped ply 144 are made with
another supportive, low-stretch fabric such as powernet.
[0046] M-shaped ply 154 with two cutouts 156 joins with W-shaped
ply 144 (and/or other layers or components of bra 100) along a
bottom edge 158, along a top edge 160 and along lateral edges 162.
Plies 144 and 154 may also be joined at center seams 164 (FIG. 4).
When plies 144 and 154 are overlaid and secured together to form
2-ply structural support layer 140, cutouts 146 and 156 form
circular openings or pockets 166 (FIG. 4). In one embodiment,
nipple covers 168 join with support layer 140 to cover pockets 166,
thus padding and reducing appearance of a wearer's nipples. FIG. 7
shows nipple covers 168 attached with structural support layer 140.
Nipple covers are for example made of slightly molded polyester,
and in one aspect, are about two inches in diameter.
[0047] Support layer 140 may be heat melded, sewn, adhered or
otherwise adjoined into bra 100, for example joining with shoulder
straps 110, sides of bra 100, optionally, with band 112 and with
liner 120. In one aspect, support layer 140 may also join directly
with exterior shell 103; however, a spacer layer may also lie
between structural support layer 140 and exterior shell 103, as
illustrated in FIG. 8. Because structural support layer 140 is
joined with bra 100 between liner 120 and exterior shell 103 (with
or without the spacer layer), it does not contact the wearer's skin
and is not readily visible to the wearer. In one aspect, support
layer 140 is sewn directly to shoulder straps 110 and adjacent
layers and surfaces with a flat lock, zigzag or other stitch that
encourages adjacent layers and surfaces to lie flat against one
another. Connecting support layer 140 with straps 110 provides
sling-type support under and around each breast, supporting the
Cooper's ligaments and aiding in stabilizing the breasts. Support
layer 140 additionally encapsulates the breasts to minimize
side-to-side and up-and-down bouncing. Molded cups 124, which fit
into pockets 166, enhance encapsulation support.
[0048] FIG. 8 is a pre-assembly view of bra 100 featuring an
additional spacer layer 170 between support layer 140 and exterior
shell 103. Spacer layer 170 is formed with a spongy nylon/spandex
fabric blend, a soft stabilizing tricot, a lightweight foam, tech
sheen or another active wear fabric. In one aspect, spacer layer
170 is formed of a naturally wicking material for wicking moisture
from within bra 100 to exterior shell 103. Spacer layer 170 helps
to minimize the appearance of a wearer's nipples under bra 100.
Spacer layer 170 may be molded to a desired shape to enhance
appearance of bra 100 and/or increase support. Exterior shell 103,
spacer layer 170, support layer 140 (with nipple covers 168
attached) and liner 120 may be sewn together at once, for example
using a stitch that encourages adjacent surfaces to lie flat
against one another. Alternately, spacer layer 170, support layer
140 and liner 120 may first be joined together, and the joined
structure sewn to exterior shell 103.
[0049] FIG. 9 is a skin-side up, schematic drawing showing support
layer 140 and spacer layer 170 assembled with front exterior shell
103. Nipple covers 168 are not included in FIG. 9, in order to show
spacer layer 170 through pockets 166. FIG. 10 is a skin-side up,
schematic drawing of front side 102 with innermost liner 120 atop
structural support layer 140. When bra 100 is worn, liner 120
contacts the wearer's skin.
[0050] As shown, liner 120 may include right and left strap liners
126A and 126B, for lining right and left straps 110A and 110B.
Strap liners 126 may be strips of spongy spacer material, each
strip extending from an upper front panel 130 at a front shoulder
seam 128, running along the skin-side of right strap 110A or left
strap 110B and attaching with an inner, back surface of bra 100
(i.e., the interior of back side 104, FIG. 2). In one aspect, strap
liners 126 connect with the inner back surface of bra 100 at rear
shoulder junctions/seams 121 (see FIG. 2). Strap liners 126 may
alternately may extend across a greater portion of the inner back
surface of bra 100, for example where the straps overlie a user's
shoulder blades, or where the back surface of bra 100 includes
continuous straps that cross over the wearer's back. In a
cross-back style, it will be appreciated that rear shoulder
junctions 121 may be placed proximate the bottom of a wearer's
shoulder blades.
[0051] In one embodiment, liner 120 includes a side panels 132
lateral to each cup 124. In one aspect, panels 130 and 132 are made
with a spacer material similar or identical to that &liming
cups 124 (i.e., the slightly spongy, nylon/ spandex material
mentioned above.
[0052] During motion, bra 100 stabilizes the breasts and minimizes
upward, downward and side-to-side bounce. W-shaped ply 144 of
support layer 140 reduces lateral and downward breast motion during
movement, while m-shaped ply 154 reduces lateral and upward motion.
Support layer 140 encapsulates the breasts to reduces both
side-to-side and up-and-down bouncing. M-shaped ply 154
additionally provides suspensory support via its attachment to
straps 110 of bra 100 (described above). Compression fabric of
shell 103 presses the breasts against the wearer's chest to further
limit motion. Exterior shell 103 is for example made with a single
jersey, 4-way stretch circular knit, yarn wicking fabric, to
provide compression and moisture management through elastic and
wicking properties of the fabric, respectively. In one aspect,
fabric of exterior shell 103 is 79% polyester COOLMAX.RTM. and 21%
Lycra.RTM..
[0053] Layers and components of bra 100 (e.g., exterior shell 103,
back 104, front liner layer 120, 2-ply structural support layer 140
(m- and w-shaped plies 154 and 144, respectively) or middle support
layer 240 (support bands 242-248), shoulder straps 110, band 112,
etc.) are adjoined by sewing, heat adjoining or any other suitable
method for adjoining fabrics. The regions where any two segments of
bra 100 are adjoined are called seams. In one aspect, all seams of
bra 100 are flat lock stitched or otherwise stitched in such a way
that they lie flat and preferably are sewn such that the edges of
adjoining pieces are faced inward toward and against the garment
fabric itself, as opposed to rubbing against the wearer's skin. For
example, in cases where seams show, they face outward on the
external portions of the garment and not against the wearer's skin,
in order to reduce the likelihood of rubbing or chafing.
[0054] Bra 100 is sewn or otherwise adjoined into one piece and is
put on by pulling over the wearer's head and shoulders. A wearer
for example pulls the bra over the head and down over the breasts,
lifting each breast into the appropriate molded cups 124 and then
adjusting position of band 112 and straps 110 as necessary. Bra 100
may be removed by simply gripping band 112, stretching it outward
and pulling it up and over the head. By eliminating eyehooks,
zippers, Velcro.RTM. and other common fasteners, bra 100 reduces
chafing, rubbing, pressure marks and abrasions that might be caused
by such fasteners rubbing against the wearer's skin.
Advantageously, the continuous, one piece design of bra 100 also
reduces bra failure, as there are no temporary fasteners to break,
bend or over stretch.
[0055] FIG. 11 shows an alternate middle support layer 240, which
may for example replace support layer 140 in bra 100 or provide
support in an alternate sports bra. Middle support layer 240 is
shown attached with an inner front side of a sports bra 200 (which
is similar to bra 100), with a liner contact side 241 facing
towards the viewer. Layer 240 includes a plurality of support bands
242-248 arranged in a figure eight pattern. Support band 242
extends from the lower left side of middle support layer 240
(proximate a left arm-hole 218B), forms a first arc for fitting
beneath a wearer's left breast, and extends upwards and across
middle support layer 240 to attach proximate an upper border of a
right arm-hole 218A, forming a second arc for fitting over a
wearer's right breast. Support band 244 extends from the lower
right side of middle support layer 240 (proximate armhole 218A),
forms a first arc for fitting beneath a wearer's right breast, and
extends upwards and across middle support layer 240 to attach
proximate upper left aim-hole 218B. Upper right, and left bands 246
and 248 underlie support bands 242 and 244. Middle support layer
240 fits with the inner front side of bra 200 such that upper right
and left bands 246 and 248 attach with lower aspects of bands 244
and 242, respectively, and extend along armholes 218A/218B and
across inner surfaces of right and left shoulder straps 210A and
210B of bra 200. Bands 242-248 are joined together in a figure
eight shape, for example by stitching. In one aspect, top edges of
upper right and left bands 246 and 248 correspond approximately
with shoulder seams of bra 200 (not labeled).
[0056] Together, bands 242-248 provide upper, lower, middle and
lateral support for each breast. Bands 242-248 of middle support
layer 240 effectively separate and support the breasts,
encapsulating each breast into its own "pocket." Middle support
layer 240 also provides sling-type support under and around each
breast, when joined with straps 210 and other components of bra
200. Bands 242-248 suspend breast tissue and support the Cooper's
ligaments via their attachment with shoulder straps 210 and sides
of bra 200. Bands 242-248 are for example made of a tech sheen
material created of about 77% denier nylon and 23% Lycra.RTM.. In
one example, the nylon is EFA Style 5481 40/13 865 SD nylon. Such
tech sheen has very low up-and-down elasticity and stretchability
and moderate side-to-side elasticity and stretchability, and
therefore maintains its shape and support of the breasts over time.
Alternately, bands 242-248 are made with another supportive,
low-stretch fabric such as powernet. Lower panels 252 of bra 200
connect adjoined support bands 242-248 with a bra band 212 when bra
200 is assembled.
[0057] The figure eight shape of middle support layer 240 may be
heat melded, sewn, adhered or otherwise adjoined into bra 200, for
example joining with any or all of shoulder straps 210, sides of
bra 200, the inside front of bra 200, bra band 212 and any liner or
spacer layers incorporated into bra 200. Although not shown in FIG.
11, in one aspect, bra 200 includes (from outside front to inside
front) an exterior layer of compressive fabric similar to exterior
shell 103 of bra 100, a spacer layer such as spacer layer 170, for
camouflaging support bands 242-248, minimizing nipple protrusion
and additionally compressing the breasts, middle support layer 240
and a liner layer such as liner 120. Where a liner layer such as
layer 120 is used, middle support layer 240 does not contact the
wearer's skin and is not readily visible to the wearer. In one
aspect, the figure eight shape of middle support layer 240 is sewn
directly to shoulder straps 210 and adjacent layers and surfaces
with a flat lock, zigzag or other stitch that encourages adjacent
layers and surfaces to lie flat against one another.
[0058] Bands 242 and 244 provide suspension support, which is
enhanced by their connection to shoulder straps 210A and 210B, via
connection to upper right and left bands 246 and 248, and is also
enhanced by bra band 212. Bands 242-248 together provide
encapsulation-type support. Where a liner such as liner 120 is
used, support is enhanced by molded liner cups (see, e.g., cups
124) that fit into pockets 262 defined by connected bands 242-248.
Finally, bra 200 has sufficient elasticity to fit tightly with the
body after being stretched during try-on, providing
compression-type support to a wearer's breasts (for example,
compression is provided by the front of bra 200 and may be enhanced
by a sufficiently elastic back side as well).
[0059] During motion, bra 200 stabilizes the breasts and minimizes
upward, downward and side-to-side bounce. Where middle support
layer 240 is incorporated into a sports bra, upper right and left
bands 246 and 248 reduce lateral motion, while bands 242 and 244
reduce upward and downward breast motion. Bands 242 and 244
additionally provide the suspensory support described above, and
additionally cross between the breasts to further stabilize and aid
in reducing side-to-side bounce. Compression provided by the
exterior fabric of bra 200 (and enhanced by any additional spacer
layer) presses the breasts against the wearer's chest to further
limit motion. Exterior bra fabric may be a single jersey, 4-way
stretch circular knit, yarn wicking fabric, to provide compression
and moisture management through elastic and wicking properties of
the fabric, respectively. In one aspect, bra 200 is made with 79%
polyester COOLMAX.RTM. and 21% Lycra.RTM.. Like bra 100, layers and
components of bra 200 are adjoined by sewing, heat adjoining or any
other suitable method for adjoining fabrics. Seams of bra 200 may
be flat lock stitched or otherwise stitched in such a way that they
lie flat and preferably are sewn such that the edges of adjoining
pieces are faced inward toward and against the garment fabric
itself, as opposed to rubbing against the wearer's skin.
[0060] Bra 200 is sewn or otherwise adjoined into one piece and is
put on by pulling over the wearer's head and shoulders. A wearer
for example pulls the bra over the head and down over the breasts,
lifting each breast into the appropriate molded cups (i.e., cups
124) and then adjusting position of band 212 and straps 210 as
necessary. Bra 200 may be removed by simply gripping band 212,
stretching it outward and pulling it up and over the head. By
eliminating eyehooks, zippers, Velcro.RTM. and other common
fasteners, bra 200 reduces chafing, rubbing, pressure marks and
abrasions that might be caused by such fasteners rubbing against
the wearer's skin Advantageously, the continuous, one piece design
of bra 200 also reduces bra failure, as there are no temporary
fasteners to break, bend or over stretch.
[0061] FIGS. 12 and 13 are respective front and back views of an
assembled bra 300, which differs in design from bra 100 but
includes all support layers and components described with respect
thereto (e.g., exterior shell 103, support layer 140 liner 120,
straps 110, band 112, etc.). Like components are given like
numbering. Whereas bra 100 was primarily described as having
shoulder straps 110 that adjoined with back 104 at a wearer's upper
back, bra 300 has continuous straps 310 that cross and join with
right and left side panels 332A and 332B (similar to panels 132 of
bra 100) to form back 304 of bra 300. Thus, rear shoulder junctions
321 of bra 300 are proximate the bottom of a wearer's shoulder
blades. As shown, shoulder straps 310 form a rear opening 323 to
facilitate ventilation and cooling. In one aspect, straps 310A and
310 B are bar tacked at a rear intersection or overlap 322 (shown
bounded by a dotted line), for example at points 324 A-D. Bar
tacking reduces movement and overall elasticity of straps 310, thus
enhancing support of bra 300. On the front exterior of bra 300,
shoulder straps 310A and 310B join seamlessly with exterior layer
303. For example, straps 310 and the majority fabric of exterior
layer 303 form the front and back exterior of bra 300. It will be
appreciated that middle support and liner layers (e.g., support
layer 140 and liner 120) may join with bra 300 at seams invisible
from the outside of bra 300.
[0062] FIG. 13 shows alternate front styling of a sports bra 300
that incorporates structural and support features of bra 100 (e.g.,
structural support layer 140, liner 120 and spacer layer 170).
Although shown with a center, front panel 302 that does not divide
bra 300 into right and left halves, it will be appreciated that
support layer 140 and liner 120 within bra 300 provide separation,
encapsulation and suspension of a wearer's breasts as described
above, while fabric of an exterior layer 303 compresses the breasts
and underlying layers of bra 300 for additional support.
[0063] FIG. 14 is a front view of an alternately styled sports bra
400, which incorporates interior features of bra 100. Bra 400 is
shown with an exterior shell 403 of a front side 402 facing out.
FIGS. 15-16 and 17-18 are front and back views of sports tanks 500
and 600 (respectively) incorporating support and structural
features of bra 100. Sports tank 500 incorporates a bra 501 that
includes support features of bra 100. For example, although not
shown, tank 500 includes a mid-layer support with overlaid m-shaped
and w-shaped layers (i.e., structural support layer 140) for
providing suspension and encapsulation support, and may also
include an interior liner layer with seamless, molded cups (i.e.,
liner 120) for further encapsulating a wearer's breasts. Fabric of
an exterior layer 503 enhances support by lending compression to
the suspension and encapsulation of tank 500. A trunk portion 513
extends from bra 501 to cover part or all of a user's stomach,
sides and mid to lower back. It will be appreciated that trunk
portion 513 may be sewn or otherwise bonded with a ribcage band
(e.g., band 112, FIGS. 1-2) of incorporated bra 501, either over or
under the band so that the band is alternately visible or invisible
when tank 500 is worn. Trunk portion 513 may be made from a
lightweight, stretchable performance fabric that conforms to the
wearer's body and wicks moisture to keep the wearer cool and dry
during exercise. FIGS. 17 and 18 show alternate styling for a
sports tank 600 incorporating bra 100 or a differently-styled bra
with a middle support layer and other bra layers and features
described herein above.
[0064] FIG. 19 illustrates a method 700 of fabricating a sports
bra. It will be appreciated that the steps of method 700 may be
carried out in an order other than that laid out below.
[0065] In steps 702-706 (outlined by dashed box 701), a bra liner
is formed. In step 702, two pre-molded, rounded or slightly
bullet-shaped bra cups are fitted into a liner or spacer material,
such that un-molded spacer material extends beyond the molded cups
to form an inside liner for other areas of a sports bra (such as
the upper chest, the area between the breasts, the ribcage lateral
to the breasts, the shoulder straps and/or the ribcage below the
breasts). The cups may be heat molded or otherwise molded. The
additional spacer material extending from the cups is trimmed into
a desired shape and desired dimensions, in step 704. Optionally,
the cups and/or complete bra liner is treated with a wicking agent,
in step 706. The spacer material used in steps 702-704 is for
example a spongy nylon/spandex fabric blend, a soft stabilizing
tricot, tech sheen or another active wear fabric such as a
lightweight wicking foam or other material able to hold its shape
after molding. It will be appreciated that the steps of forming a
bra liner may be carried out in an order other than shown in FIG.
19. For example, the liner may be cut to shape prior to placement
of pre-molded cups.
[0066] A mid-layer support structure is formed in steps 708-714
(outlined by dashed box 703). In step 708, a layer of supportive
fabric is cut to form a roughly m-shaped layer. In step 710, a
roughly w-shaped layer is cut from the same or different supportive
fabric, at a different grain than the m-shaped layer. For example,
if the m-shaped layer is cut cross grain, the w-shaped layer is cut
straight grain, and vice versa. In step 712, the m- and w-shaped
layers are sewn together such that open areas farmed by each
"letter" overlap to form openings for accommodating a wearer's
nipple area. Nipple covers are sewn over the openings, in step 714.
In one example of steps 708-714, m-shaped ply 154 is cut
cross-grain from tech sheen, and w-shaped ply 144 is cut straight
grain from the tech sheen. Ply 154 is laid over ply 144 (or vice
versa) such that cutouts 156 and 146 overlap to form pockets 166,
and the layers are joined with a flat lock, zigzag or other stitch
that encourages plies 154 and 144 to lie flat against one another.
Nipple covers 168, which may be pre-made or formed as an additional
step of method 700, are sewn over pockets 166.
[0067] The liner and mid-layer support structure are joined
together, in step 716. In one example of step 716, support layer
140 is fitted over cups 124 formed in steps 602-606 such that
nipple covers 168 fit over a nipple area or apex of the cups, and
the liner and support layer are sewn together, e.g., along a
perimeter of the support layer and liner, and optionally, about the
molded cups and/or down a centerline between the cups as well.
[0068] An exterior sports bra layer is formed in steps 718-722
(outlined by dotted box 705). In optional step 718, a fabric print
is custom designed. In optional step 720, the design is printed
onto a performance compression fabric, such as a dense, 4-way
stretch polyester COOLMAX.RTM. and Lycra.RTM. jersey fabric. In
step 722, the exterior fabric is cut to desired dimensions for a
front and a back of a given bra size (e.g., 36C, 34D, small, medium
or large). It will be appreciated that step 718 (fabric design)
need not occur in the sequence shown, but may be designed long
before it is printed (step 720) and the printed fabric cut (step
722). Likewise, the fabric to be cut need not be printed
immediately prior to cutting, but may be printed weeks, months or
longer before it is cut in step 722.
[0069] A spacer layer is formed, in step 724. In one example of
step 724, spacer layer 170 is cut to dimensions compatible with the
bra being formed. Spacer layer 170 is for example cut from a spongy
nylon/spandex fabric blend, a soft stabilizing tricot, a
lightweight foam, tech sheen or another active wear fabric having
wicking properties. The exterior front side of the bra is joined
with the spacer, inner liner and mid-layer support structure, in
step 726. In one example, the layers are sewn together such that
the liner forms a skin-contact side of the front of the sports bra,
the mid-layer support structure lies between the liner and the
spacer layer, and the bra exterior covers the spacer layer.
[0070] The bra is completed in steps 728 and 730, in which front
and back exterior sides of the bra are sewn together, and a ribcage
band (e.g., woven elastic) is applied about the bottom border of
the bra.
[0071] It will be appreciated that interior bra layers formed in
method 700 (for example, the liner or spacer layers) may be cut to
form strap liners. Alternately, where interior bra layers do not
extend to the bra straps, additional strap liners may be cut and
sewn with bra straps formed by the exterior bra layer.
[0072] FIG. 20 illustrates a method 800 of fabricating a sports bra
incorporating the support structure of FIG. 11. It will be
appreciated that the steps of method 800 may be carried out in an
order other than that laid out below.
[0073] In steps 802-806 (outlined by dashed box 801), a bra liner
is formed as described above with respect to steps 702-706. Bra
cups are fit into liner/spacer material in step 802, spacer
material is trimmed in step 804 and the cups and/or complete liner
is treated with a wicking agent, in step 806. See the above
description of steps 702-706 for additional details and
options.
[0074] A mid-layer figure-eight support structure is formed, in
steps 808-810 (outlined by dashed box 803). In step 808, upper and
lower support bands are joined in a figure-eight configuration, for
example by sewing with a flat lock, zigzag or other stitch that
encourages the bands to lie flat against one another. Left and
right side-to-upper bands are joined along upper/lateral aspects of
the figure-eight structure, in step 810.
[0075] The liner and mid-layer support structure are joined
together, in step 812. In one example of step 812, the pre-molded
cups of the formed liner are fitted into central pockets formed by
the figure-eight structure of steps 808-810, and the liner and
support structure are sewn together to keep the cups in place
within the figure-eight structure. For example, the figure eight
structure and the liner are sewn together along the perimeter of
the figure eight structure, and optionally, about the molded cups
as well.
[0076] An exterior sports bra layer is formed in steps 814-818
(outlined by dotted box 805). In optional step 814, a fabric print
is custom designed. In optional step 816, the design is printed
onto a performance compression fabric, and in step 818, the
exterior fabric is cut to desired shape and dimensions. See steps
718-722 of FIG. 19 for additional detail. As noted above with
respect to FIG. 19, fabric need not be designed and printed
immediately prior to cutting. Rather, these steps may occur days,
weeks, months or years prior to step 818.
[0077] A spacer layer is formed, in step 820. In one example of
step 820, spacer layer 170 is cut to dimensions compatible with the
bra being formed. Spacer layer 170 is for example cut from a spongy
nylon/spandex fabric blend, a soft stabilizing tricot, a
lightweight foam, tech sheen or another active wear fabric having
wicking properties. The exterior front side of the bra is joined
with the inner liner, mid-layer support structure and spacer, in
step 822. The layers may be sewn together such that the mid-layer
support structure is secured between the liner and bra exterior. As
with steps 728 and 730 of FIG. 19, front and back sides of the bra
are sewn together in step 824, and a ribcage band is applied about
the bottom border of the bra, in step 826.
[0078] While the present invention has been described above, it
should be clear that many changes and modifications may be made to
the process and product without departing from the spirit and scope
of this invention. For example, features of bra 100 may be combined
with any bra or sports tank described herein, or other garment
incorporating a sports bra. Alternately, different fabrics that
provide the same or similar function to those described above may
replace or compliment the specific types described herein.
* * * * *